Fiber Strength Retention of Lanthanum- and Cerium Monazite-Coated Nextel™ 720

Nextel™ 720 fibers were coated with LaPO₄ and CePO₄ monazite. The coatings were applied using washed and unwashed rhabdophane sols derived from La(NO₃)₃/(NH₄)₂HPO₄ and a washed sol derived from Ce(NO₃)₃/H₃PO₄. The coatings were cured in-line at 900°–1300°C. Multiple coatings were also applied. Fiber strength was retained after coating with washed sols, but not with unwashed sols. These results are consistent with earlier work on LaPO₄ monazite fiber coatings derived from La(NO₃)₃/H₃PO₄.     

Two Phase Monazite/Xenotime 30LaPO4–70YPO4 Coating of Ceramic Fiber Tows

Equiaxed yttrium–lanthanum phosphate nanoparticles (Y_0.7,La_0.3)PO₄·0.7H₂O were made and used to continuously coat Nextel^™ 720 fiber tows. The particles were precipitated from a mixture of yttrium and lanthanum citrate chelate and phosphoric acid (H₃PO₄), and characterized with differential thermal analysis and thermogravimetric analysis, X-ray diffraction, transmission electron microscopy, and scanning electron microscopy. The coated fibers were heat treated at 1000°–1300°C for 1, 10, and 100 h. Coating grain growth kinetics and coated fiber strengths were determined and compared with equiaxed La-monazite coatings. The relationships between coating porosity, coating hermeticity, and coated fiber strength are discussed.     

Reactivity of Alumina toward Phosphoric Acid

Reaction between alumina and 33.3 wt% orthophosphoric acid was investigated by monitoring the heat liberated under isothermal conditions at temperatures from 25° to 90°C. In a separate set of experiments, the H₃PO₄ concentration was varied from 0 to 50 wt%, at 25°C. Reactivities of five aluminas (three anhydrous and two hydrated) differing in particle size, surface area, and crystallinity were studied. Relationships between the properties of the aluminas and their reactivities toward phosphoric acid were established. The aluminas with the highest surface areas and the lowest degrees of crystallinity react more rapidly and produce overall more heat. Increasing the temperature and phosphoric acid concentration were also shown to increase heat evolution. However, increasing the H₃PO₄ concentration beyond 33.3 wt% (molar Al/P ratio = 1.0) for the anhydrous aluminas, and beyond 40 wt% for boehmite, does not result in a significant increase in the amount of heat evolved. Gibbsite continues to release greater amounts of heat when reacting with increasing concentrations of H₃PO₄ (up to 50 wt%). The anhydrous aluminas generally react faster than do the hydrates. Within the range of H₃PO₄ concentrations from 0 to 33.3 wt% the hydrates and the most reactive anhydrous alumina exhibit approximately the same degree of reactivity on a per mole of Al₂O₃ basis.     

Proton-Conductive Membranes Doped with Orthophosphoric Acid Based on Inorganic–Organic Hybrid Materials

A series of proton-conductive inorganic–organic hybrid membranes doped with phosphoric acid (H₃PO₄) have been prepared by the sol–gel process with 3-glycidoxypropyltrimethoxysilane (GPTMS), 3-aminopropyltriethoxysilane (APTES), and tetraethoxysilane (TEOS) as precursors. High proton conductivity of 3.0 × 10⁻³ S/cm with a composition of 50TEOS–30GPTMS–20APTES–50H₃PO₄ was obtained at 120°C under 50% relative humidity (RH). The differential thermal analysis curve showed that thermal stability of membrane is significantly enhanced by the presence of an SiO₂ framework up to 250°C. X-ray ray diffraction revealed that the gels were amorphous. Infrared spectra showed a good complexation of H₃PO₄ in the matrix. The porous hybrid membrane, characterized by scanning electron microscopy, shows humidity-dependent conduction, and the conductivity under 75% relative humidity was significantly improved by addition of APTES due to the increase in the concentration of the defective site in the hybrid matrix.     

Pressureless Sintering of α-Si3N4 Porous Ceramics Using a H3PO4 Pore-Forming Agent

A new method for preparing high bending strength porous silicon nitride (Si₃N₄) ceramics with controlled porosity has been developed by using pressureless sintering techniques and phosphoric acid (H₃PO₄) as the pore-forming agent. The fabrication process is described in detail and the sintering mechanism of porous ceramics is analyzed by the X-ray diffraction method and thermal analysis. The microstructure and mechanical properties of the porous Si₃N₄ ceramics are investigated, as a function of the content of H₃PO₄. The resultant high porous Si₃N₄ ceramics sintered at 1000°–1200°C show a fine porous structure and a relative high bending strength. The porous structure is caused mainly by the volatilization of the H₃PO₄ and by the continous reaction of SiP₂O₇ binder, which could bond on to the Si₃N₄ grains. Porous Si₃N₄ ceramics with a porosity of 42%–63%, the bending strength of 50–120 MPa are obtained.     

Aluminum Phosphates Derived from Alumina and Alumina-Sol–Gel Systems

Aluminum phosphate products formed by the reactions of alumina and alumina-gel systems with acidic phosphates were analyzed. Drying of alumina-gel to form microcrystalline boehmite and conversion to γ-alumina by thermal treatment was indicated by the appearance of octahedral, pentacoordinate, or tetrahedral sites, which were established using ²⁷Al magic-angle-spinning solid-state nuclear magnetic resonance spectroscopy. Crystalline aluminum phosphate products and amorphous material were identified using this technique. α-alumina and heat-treated alumina-gel that were reacted with phosphate in an Al:P ratio of 1:1 yielded dramatically different aluminum orthophosphate:aluminum metaphosphate product ratios of 8.2:1 and 1:1.1, respectively. When alumina-gel was heat-treated with phosphate, an abundance of aluminum orthophosphate, aluminum metaphosphate, and hydrated aluminum phosphate products were affected by varying conditions of temperature and time of heat treatment and by the amount of phosphate present. An α-alumina/alumina-gel composite sol–gel phase that was reacted with phosphoric acid (H₃PO₄) in a Al:P ratio of 1:1 exhibited an increased quantity of aluminum metaphosphate products compared with an α-alumina:H₃PO₄ ratio of 1:1 and a higher percentage of reaction (79%) compared with the reactions of an α-alumina:H₃PO₄ ratio of 1:1 or an alumina-gel:H₃PO₄ ratio of 1:1. The morphologies of aluminum triphosphate hydrate and aluminum metaphosphate product phases were observed using scanning electron microscopy.     

Fabrication of NiO Nanoparticle-Coated Lead Zirconate Titanate Powders by the Heterogeneous Precipitation Method

NiO nanoparticle-coated lead zirconate titanate (PZT) powders are successfully fabricated by the heterogeneous precipitation method using PZT, Ni(NO₃)₂·6H₂O, and NH₄HCO₃ as the starting materials. The amorphous NiCO₃·2Ni(OH)₂·2H₂O are uniformly coated on the surface of PZT particles. XRD analysis and the selected-area diffraction (SAD) pattern indicate that the amorphous coating layer is crystallized to NiO after being calcined at 400°C for 2 h. TEM images show that the NiO particles of ∼8 nm are spherical and weakly agglomerated. The thickness of the nanocrystalline NiO coating layer on the surface of PZT particle is ∼30 nm.     

Alumina/Epoxy Interpenetrating Phase Composite Coatings: I, Processing and Microstructural Development

Interpenetrating phase composite (IPC) coatings consisting of continuously connected Al₂O₃ and epoxy phases were fabricated. The ceramic phase was prepared by depositing an aqueous dispersion of Al₂O₃ (0.3 μm) containing orthophosphoric acid, H₃PO₄, (1–9.6 wt%, solid basis) and heating to create phosphate bonds between particles. The resulting ceramic coating was porous, which allowed the infiltration and curing of a second-phase epoxy resin. The effect of dispersion composition and thermal processing conditions on the phosphate bonding and ceramic microstructure was investigated. Reaction between Al₂O₃ and H₃PO₄ generated an aluminum phosphate layer on particle surfaces and between particles; this bonding phase was initially amorphous, but partially crystallized upon heating to 500°C. Flexural modulus measurements verified the formation of bonds between particles. The coating porosity (and hence epoxy content in the final IPC coating) decreased from ∼50% to 30% with increased H₃PO₄ loading. The addition of aluminum chloride, AlCl₃, enhanced bonding at low temperatures but did not change the porosity. Diffuse reflectance FTIR showed that a combination of UV and thermal curing steps was necessary for complete curing of the infiltrated epoxy phase. Al₂O₃/epoxy IPC coatings prepared by this method can range in thickness from 1 to 100 μm and have potential applications in wear resistance.     

Solid Solubility and Thermal Expansion in a LaPO4–YPO4 System

The composition and lattice parameters of co-precipitated (La_0.3Y_0.7) orthophosphate were studied using X-ray diffraction (XRD), transmission electron microscopy (TEM), and energy dispersive X-ray spectroscopy (EDX). The results indicate that the as-precipitated powder consists of single-phase (La_0.3Y_0.7PO₄·H₂O) rhabdophane nanoparticles. Heat treatment at 950°C caused the decomposition of rhabdophane into a (La_{1− x} Y _x )PO₄ monazite solid solution and YPO₄ xenotime. The solid solubility of Y in LaPO₄ monazite from 1000° to 1600°C was studied using XRD, TEM, and EDX. The implications of the findings for controlling the coefficient of thermal expansion of the prospective two-phase monazite–xenotime fiber coatings for ceramic composites applications are discussed.     

Spherical Rhabdophane Sols. I: Rheology and Particle Morphology

The particle morphology, weight loss, and rheology of rhabdophane (LaPO₄· n H₂O) sols with either spherical or rod-shaped particles were characterized and compared. Some spherical particle sols were doped with aluminum. Particle size was characterized by light scattering and transmission electron microscopy (TEM). The additives that promote spherical particle formation also cause greater high temperature weight loss than similar rod-shaped particle sols. As expected, the shear-rate dependence of sol viscosity was much weaker for spherical particle sols. The viscosity for sols with both types of particles was modeled using particle aspect ratios and bound water layer thicknesses as variables. A bound water layer thickness of 3–5 nm was suggested by modeling, except in aluminum-doped sols, where a much larger thickness was suggested. Modeled aspect ratios were larger than those observed by TEM. Weakly bound agglomerates may be present in both types of sols.     

Low-Temperature Formation of Aluminum Orthophosphate

Factors influencing the low-temperature formation of AIPO₄ and its precursor phases, AIPO₄· x H₂O (1 x 2), were investigated. AIPO₄ formed by reaction between 33.3 wt% H₃PO₄ solution and alumina. Five aluminas (three anhydrous and two hydrated) were utilized. Each differed in particle size, surface area, and crystallinity. The reaction temperatures investigated were 113°, 123°, and 133°C. The high-surface-area aluminas were sufficiently reactive in the phosphoric acid solution at these temperatures to produce crystalline reaction products. However, only hydrated forms of AIPO₄, AIPO₄· x H₂O (1 x 2), crystallized directly out of solution. x generally decreased as the curing temperature was increased. Upon dehydration of these hydrated reaction products, anhydrous AIPO₄ was formed, primarily in the berlinite and/or cristobalite modifications. Both the temperature of reaction and the alumina used influence the hydrates that form. In turn, the hydrates which form, the macroscopic assemblages into which they may crystallize, and the morphologies of the crystallites all affect the polymorphic form and the crystallinity of the anhydrous AIPO₄ phase ultimately produced on dehydration. Phase-pure and highly crystalline AIPO₄-cristobalite (the high-temperature modification) was formed by the dehydration of AIPO₄·H₂O at a temperature as low as 113°C.     

Uniformly Porous Al2O3/LaPO4 and Al2O3/CePO4 Composites with Narrow Pore-Size Distribution

Porous Al₂O₃/20 vol% LaPO₄ and Al₂O₃/20 vol% CePO₄ composites with very narrow pore-size distribution at around 200 nm have been successfully synthesized by reactive sintering at 1100°C for 2 h from RE₂(CO₃)₃· x H₂O (RE = La or Ce), Al(H₂PO₄)₃ and Al₂O₃ with LiF additive. Similar to the previously reported UPC-3Ds (uniformly porous composites with a three-dimensional network structure, e.g. CaZrO₃/MgO system), decomposed gases in the starting materials formed a homogeneous open porous structure with a porosity of ∼40%. X-ray diffraction, ³¹P magic-angle spinning nuclear magnetic resonance, scanning electron microscopy, and mercury porosimetry revealed the structure of the porous composites.     

Spray Pyrolysis of Fe3O4–BaTiO3 Composite Particles

Fe₃O₄–BaTiO₃ composite particles were successfully prepared by ultrasonic spray pyrolysis. A mixture of iron(III) nitrate, barium acetate and titanium tetrachloride aqueous solution were atomized into the mist, and the mist was dried and pyrolyzed in N₂ (90%) and H₂ (10%) atmosphere. Fe₃O₄–BaTiO₃ composite particle was obtained between 900° and 950°C while the coexistence of FeO was detected at 1000°C. Transmission electron microscope observation revealed that the composite particle is consisted of nanocrystalline having primary particle size of 35 nm. Lattice parameter of the Fe₃O₄–BaTiO₃ nanocomposite particle was 0.8404 nm that is larger than that of pure Fe₃O₄. Coercivity of the nanocomposite particle (390 Oe) was much larger than that of pure Fe₃O₄ (140 Oe). These results suggest that slight diffusion of Ba into Fe₃O₄ occurred.     

Sol–Gel Synthesis and Microstructure Analysis of Amino-Modified Hybrid Silica Nanoparticles from Aminopropyltriethoxysilane and Tetraethoxysilane

Agglomerated amino-modified silica nanoparticles were prepared from a novel Stöber-like precursor system consisting of aminopropyltriethoxysilane (APTES), tetraethoxysilane (TEOS), ethanol, and water where the molar ratio APTES/TEOS was 0, 0.1, 1.0, and 2.0, and the molar ratio H₂O/-SiOC₂H₅ was about 20 to 60, or great excess amounts of H₂O were employed. APTES catalyzed the hydrolysis and condensation of both silanes. ²⁹Si magic angle spinning nuclear magnetic resonance spectra confirmed that the particles consisted of Qⁿ species (Si(OSi) _n (OH)_{4− n} ; n =2, 3, 4) and Tⁿ species (NH₂(CH₂)₃–Si(OSi) _n (OH)_{3− n} ; n =2, 3). The APTES content in the precursor solutions controlled the agglomerating spherical particle size and morphology: 0.1 in the ratio APTES/TEOS led to almost independent spheres of 300–400 nm, while the larger ratios 1 and 2 led to ∼250 and ∼150 nm spheres, respectively, that were largely agglomerated and some were fused to look like peanut-shells. When soaked in Kokubo's simulated body fluid, those amino-modified particles deposited apatite. The mechanisms of particle formation and apatite deposition were discussed in terms of an intraparticle hydrated layer.     

Wet-Chemical Routes Leading to Scandia Nanopowders

Two wet-chemical routes have been used to synthesize Sc₂O₃ nanopowders from nitrate solutions employing ammonia water (AW) and ammonium hydrogen carbonate (AHC) as the precipitants. The precursors and the resultant oxides are characterized by elemental analysis, X-ray diffractometry, differential thermal analysis/thermogravimetry, high-resolution scanning electron microscopy, and Brunauer-Emmett-Teller analysis. Crystalline γ-ScOOH· n H₂O ( n ≈ 0.5) is the only phase obtained by the AW method. This phase dehydrates to Sc₂O₃ at ∼400°C, yielding hard aggregated nanocrystalline Sc₂O₃ powders. Three types of precursors have been synthesized by the AHC method, depending on the AHC/Sc³⁺ molar ratio ( R ): amorphous basic carbonate [Sc(OH)CO₃·H₂O] at R ≤ 3, crystalline double carbonate [(NH₄)Sc(CO₃)₂·H₂O] at R ≥ 4, and a mixture of the two phases at 3 < R < 4. Among these precursors, only the basic carbonate shows spherical particle morphology, ultrafine particle size (∼50 nm), and weak agglomeration. Sc₂O₃ nanopowders (∼28 nm) with high surface area (∼49 m²/g) have been prepared by calcining the basic carbonate at 700°C for 2 h.     

Electroceramics from Source Materials via Molecular Intermediates: PbTiO3 from TiO2 via [Ti(catecholate)3]2-

The precursor [NH₄]₂[Ti(catecholate)₃] · 2H₂O is known to react with Ba(OH)₂· 8H₂O in an acid/base process that generates Ba[Ti(catecholate)₃] · 3H₂O, a compound which undergoes low-temperatue calcination to produce BaTiO₃ powder. Attempts to develop similar routes to PbTiO₃ have been frustrated, since lead(II) hydroxide does not exist. The amphoteric yellow PbO and the basic oxide, Pb₆O(OH)₆⁴⁺, are both insufficiently basic to react with [NH₄]₂[Ti(catecholate)₃] · 2H₂O. Based on the large sizes of both the [Ti(catecholate)₃]^2- anion and the Pb²⁺ cation, a precipitation method has been developed in which lead nitrate and [NH₄]₂[Ti(catecholate)₃] · 2H₂O are added together in an aqueous medium causing precipitation and leaving only NH₄NO₃ in solution. The lead-titanium-catecholate complex that forms in this manner undergoes low-temperature pyrolysis to produce PbTiO₃. SEM indicates a submicrometer ultimate crystallite size.     

Gelcasting of Magnesium Aluminate Spinel Powder

A stoichiometric MgAl₂O₄ spinel (MAS) powder was processed in aqueous media and consolidated by gelcasting from suspensions containing 41–45 vol% solids loading. The MAS powder was first obtained by heat treating a compacted mixture of α-Al₂O₃ and calcined caustic MgO at 1400°C for 1 h, followed by crushing and milling. Then, its surface was passivated against hydrolysis using an ethanol solution of H₃PO₄ and Al(H₂PO₄)₃. The as-treated surface MAS powder could then be dispersed in water using tetra methyl ammonium hydroxide and an ammonium salt of poly-acrylic acid (Duramax D-3005) as dispersing agents. The as-obtained stable suspensions were gelcast, dried, and sintered at 1650°C for 1–3 h. For comparison purposes, the treated powder was also compacted by die pressing of freeze-dried granules and sintered along with gelcast samples. Near-net-shape MAS components with 99.55% of the theoretical density could be fabricated by aqueous gelcasting upon sintering at 1650°C for 3 h. The MAS ceramics fabricated by gelcasting and die pressing exhibited comparable properties.     

Particle Size Control and Dependence on Precursor pH: Synthesis Uniform Submicrometer Zinc Aluminate Particles

Zinc aluminate (ZnAl₂O₄) particles have been synthesized by the hydrothermal method using NH₃·H₂O as a pH adjustment mineralizer. Experimental results showed that ZnAl₂O₄ particle size was dependent on the precursor pH, and could be controlled through pH adjustment. It was 5.5, 11.5, and 27 nm when the precursor pH was 8.2, 9.3, and 10.5, respectively. On the other hand, the particle size distribution changed broader with increase in pH. These differences were attributable to the different NH₃·H₂O function. NH₃·H₂O was mainly used as a base at lower pH (<9.0), while its complex function predominated at higher one (>9.5). From thermodynamic viewpoint, the rate-limiting steps were dissolution of Al(OH)₃ and γ-AlO(OH) to Al(OH)₄⁻ at lower and higher pH, respectively. The newly formed γ-AlO(OH) with high reactivity was the critical factor in the synthesis of bimodal particles. Higher temperature treatment of γ-AlO(OH) could decrease the reactivity, and could be used as an aluminum source for synthesis uniform ZnAl₂O₄ particles.     

Synthesis of Nanosize-Necked Structure α- and γ-Fe2O3 and its Photocatalytic Activity

Highly dispersed nanometer-sized α-Fe₂O₃ (hematite) and γ-Fe₂O₃ (maghemite) iron oxide particles were synthesized by the combustion method. Ferric nitrate was used as a precursor. X-ray diffractometer study revealed the phase purity of α- and γ-Fe₂O₃. Both the products were characterized using field emission scanning electron microscope and transmission electron microscope for particle size and morphology. Necked structure particle morphology was observed for the first time in both the iron oxides. The particle size was observed in the range of 25–55 nm. Photodecomposition of H₂S for hydrogen generation was performed using α- and γ-Fe₂O₃. Good photocatalytic activity was obtained using α- and γ-Fe₂O₃ as photocatalysts under visible light irradiation.     

Preparation of Calcium Lanthanum Sulfide Powders via Alkoxide Sulfurization

Calcium lanthanum sulfide powders were prepared by reacting methoxides of calcium and lanthanum with H₂S. Alkoxide mixtures of various La/Ca ratios dispersed in methanol were reacted with H₂S at 25° to 85°C and the amorphous gels obtained after the removal of methanol were heat-treated in H₂S for full sulfurization at various temperatures. Up to 500°C, cubic LaS₂ was the only crystalline phase present. Calcium lanthanum sulfide phase started to form at 550°C. In the temperature range of 650° to 750°C, single-phase calcium lanthanum sulfide powders were obtained for La/Ca = 2.41 and 2.68.